Clean-in-place
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Clean-in-place (CIP) is an automated method of cleaning the interior surfaces of pipes, vessels, equipment,
filters Filter, filtering or filters may refer to: Science and technology Computing * Filter (higher-order function), in functional programming * Filter (software), a computer program to process a data stream * Filter (video), a software component tha ...
and associated fittings, without major disassembly. CIP is commonly used for equipment such as piping, tanks, and fillers. CIP employs turbulent flow through piping, and/or spray balls for large surfaces. In some cases, CIP can also be accomplished with fill, soak and agitate. Up to the 1950s, closed systems were disassembled and cleaned manually. The advent of CIP was a boon to industries that needed frequent internal cleaning of their processes. Industries that rely heavily on CIP are those requiring high levels of hygiene, and include:
dairy A dairy is a business enterprise established for the harvesting or processing (or both) of animal milk – mostly from cows or buffaloes, but also from goats, sheep, horses, or camels – for human consumption. A dairy is typically located on ...
,
beverage A drink or beverage is a liquid intended for human consumption. In addition to their basic function of satisfying thirst, drinks play important roles in human culture. Common types of drinks include plain drinking water, milk, juice, smoothies a ...
,
brewing Brewing is the production of beer by steeping a starch source (commonly cereal grains, the most popular of which is barley) in water and #Fermenting, fermenting the resulting sweet liquid with Yeast#Beer, yeast. It may be done in a brewery ...
,
processed foods Convenience food, also called tertiary processed food, is food that is commercially prepared (often through processing) to optimise ease of consumption. Such food is usually ready to eat without further preparation. It may also be easily por ...
,
pharmaceutical A medication (also called medicament, medicine, pharmaceutical drug, medicinal drug or simply drug) is a drug used to diagnose, cure, treat, or prevent disease. Drug therapy (pharmacotherapy) is an important part of the medical field and re ...
, and
cosmetics Cosmetics are constituted mixtures of chemical compounds derived from either natural sources, or synthetically created ones. Cosmetics have various purposes. Those designed for personal care and skin care can be used to cleanse or protect ...
. The benefit to industries that use CIP is that the cleaning is faster, less labor-intensive and more repeatable, and poses less of a chemical exposure risk. CIP started as a manual practice involving a balance tank,
centrifugal pump Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an engine or electric motor. They are a sub-class of dynamic ...
, and connection to the system being cleaned. Since the 1950s, CIP has evolved to include fully automated systems with
programmable logic controller A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity tha ...
s, multiple balance tanks,
sensors A sensor is a device that produces an output signal for the purpose of sensing a physical phenomenon. In the broadest definition, a sensor is a device, module, machine, or subsystem that detects events or changes in its environment and sends ...
,
valves A valve is a device or natural object that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are technically fitting ...
,
heat exchangers A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct conta ...
,
data acquisition Data acquisition is the process of sampling signals that measure real-world physical conditions and converting the resulting samples into digital numeric values that can be manipulated by a computer. Data acquisition systems, abbreviated by the acro ...
and specially designed spray nozzle systems. Simple, manually operated CIP systems can still be found in use today. Depending on soil load and process geometry, the CIP design principle is one of the following: * deliver highly turbulent, high flow-rate solution to effect good cleaning (applies to pipe circuits and some filled equipment). * deliver solution as a low-energy spray to fully wet the surface (applies to lightly soiled vessels where a static sprayball may be used). * deliver a high energy impinging spray (applies to highly soiled or large diameter vessels where a dynamic spray device may be used). Elevated temperature and chemical detergents are often employed to enhance cleaning effectiveness.


Factors affecting the effectiveness of the cleaning agents

Temperature of the cleaning solution. Elevating the temperature of a cleaning solution increases its dirt removal efficiency. Molecules with high kinetic energy dislodge dirt faster than the slow moving molecules of a cold solution. Concentration of the cleaning agent. A concentrated cleaning solution will clean a dirty surface much better than a dilute one due to the increased surface binding capacity. Contact time of the cleaning solution. The longer the detergent contact period, the higher the cleaning efficiency. After some time, the detergent eventually dissolves the hard stains/soil from the dirty surface. Pressure exerted by the cleaning solution (or turbulence). The turbulence creates an abrasive force that dislodges stubborn soil from the dirty surface.


Groundwater sources

Originally developed for cleaning closed systems as described above, CIP has more recently been applied to
groundwater Groundwater is the water present beneath Earth's surface in rock and soil pore spaces and in the fractures of rock formations. About 30 percent of all readily available freshwater in the world is groundwater. A unit of rock or an unconsolidate ...
source
borehole A borehole is a narrow shaft bored in the ground, either vertically or horizontally. A borehole may be constructed for many different purposes, including the extraction of water ( drilled water well and tube well), other liquids (such as petrol ...
s used for high end-uses such as natural mineral/spring waters, food production and carbonated soft drinks (CSD). Boreholes that are open to the atmosphere are prone to a number of chemical and microbiological problems, so sources for high end-use are often sealed at the surface (
headworks Headworks is a civil engineering term for any structure at the head or diversion point of a waterway. It is smaller than a barrage and is used to divert water from a river into a canal or from a large canal into a smaller canal. at Web archive An ...
). An air filter is built into the headworks to permit the borehole to inhale and exhale when the water level rises and falls quickly (usually due to the pump being turned on and off) without drawing in airborne particles or contaminants (spores, molds, fungi, bacteria, etc.). In addition, CIP systems can be built into the borehole headworks to permit the injection of cleaning solutions (such as
sodium hypochlorite Sodium hypochlorite (commonly known in a dilute solution as bleach) is an Inorganic chemistry, inorganic chemical compound with the chemical formula, formula NaOCl (or NaClO), comprising a sodium cation () and a hypochlorite anion (or ). It may ...
or other
sanitizer A disinfectant is a chemical substance or compound used to inactivate or destroy microorganisms on inert surfaces. Disinfection does not necessarily kill all microorganisms, especially resistant bacterial spores; it is less effective than st ...
s) and the subsequent recirculation of the mix of these chemicals and the groundwater. This process cleans the borehole interior and equipment without any invasive maintenance being required.


Biomanufacturing Equipment

CIP is commonly used for cleaning bioreactors, fermenters, mix vessels, and other equipment used in biotech manufacturing, pharmaceutical manufacturing and food and beverage manufacturing. CIP is performed to remove or obliterate previous mammalian
cell culture Cell culture or tissue culture is the process by which cells are grown under controlled conditions, generally outside of their natural environment. The term "tissue culture" was coined by American pathologist Montrose Thomas Burrows. This te ...
batch components. It is used to remove in-process residues, control
bioburden Bioburden is normally defined as the number of bacteria living on a surface that has not been sterilized. The term is most often used in the context of bioburden testing, also known as microbial limit testing, which is performed on pharmaceutical ...
, and reduce
endotoxin Lipopolysaccharides (LPS) are large molecules consisting of a lipid and a polysaccharide that are bacterial toxins. They are composed of an O-antigen, an outer core, and an inner core all joined by a covalent bond, and are found in the outer ...
levels within processing equipment and systems. Residue removal is accomplished during CIP with a combination of heat, chemical action, and
turbulent flow In fluid dynamics, turbulence or turbulent flow is fluid motion characterized by chaotic changes in pressure and flow velocity. It is in contrast to a laminar flow, which occurs when a fluid flows in parallel layers, with no disruption between ...
. The
U.S. Food and Drug Administration The United States Food and Drug Administration (FDA or US FDA) is a federal agency of the Department of Health and Human Services. The FDA is responsible for protecting and promoting public health through the control and supervision of food ...
published a CIP regulation in 1978 applicable to pharmaceutical manufacturing. The regulation states, "Equipment and utensils shall be cleaned, maintained, and sanitized at appropriate intervals to prevent malfunctions or contamination that would alter the safety, identity, strength, quality or purity of the drug product beyond the official or other established requirements." Repeatable, reliable, and effective cleaning is of the utmost importance in a manufacturing facility. Cleaning procedures are validated to demonstrate that they are effective, reproducible, and under control. In order to adequately clean processing equipment, the equipment must be designed with smooth stainless steel surfaces and interconnecting piping that has cleanable joints. The chemical properties of the cleaning agents must properly interact with the chemical and physical properties of the residues being removed. A typical CIP cycle consists of many steps which often include (in order): * Pre-rinse with WFI (water for injection) or PW (
purified water Purified water is water that has been mechanically filtered or processed to remove impurities and make it suitable for use. Distilled water was, formerly, the most common form of purified water, but, in recent years, water is more frequently puri ...
) which is performed to wet the interior surface of the tank and remove residue. It also provides a non-chemical pressure test of the CIP flow path. *
Caustic Caustic most commonly refers to: * Causticity, a property of various corrosive substances ** Sodium hydroxide, sometimes called ''caustic soda'' ** Potassium hydroxide, sometimes called ''caustic potash'' ** Calcium oxide, sometimes called ''caus ...
solution single pass flush through the vessel to drain. Caustic is the main cleaning solution. * Caustic solution re-circulation through the vessel. * Intermediate WFI or PW rinse * Acid solution wash – used to remove mineral precipitates and protein residues. * Final rinse with WFI or PW – rinses to flush out residual cleaning agents. * Final air blow – used to remove moisture remaining after CIP cycle. Critical parameters must be met and remain within the specification for the duration of the cycle. If the specification is not reached or maintained, cleaning will not be ensured and will have to be repeated. Critical parameters include temperature, flow rate/supply pressure, chemical concentration, chemical contact time, and final rinse
conductivity Conductivity may refer to: *Electrical conductivity, a measure of a material's ability to conduct an electric current **Conductivity (electrolytic), the electrical conductivity of an electrolyte in solution **Ionic conductivity (solid state), elec ...
(which shows that all cleaning chemicals have been removed).


See also

*
Effluent guidelines Effluent Guidelines (also referred to as Effluent Limitation Guidelines (ELGs)) are U.S. national standards for wastewater discharges to surface waters and publicly owned treatment works (POTW) (also called municipal sewage treatment plants). The Un ...
(U.S. wastewater regulations) *
Effluent limitation An effluent limitation is a United States Clean Water Act standard of performance reflecting a specified level of discharge reduction achievable by the best available technology or related standards for various sources of water pollution. These so ...
*
Good manufacturing practice Current good manufacturing practices (cGMP) are those conforming to the guidelines recommended by relevant agencies. Those agencies control the authorization and licensing of the manufacture and sale of food and beverages, cosmetics, pharmaceutica ...
* Ice pigging *
Washdown Washdown (also wash down) is the process of cleaning or washing a surface for appearance, sanitation, or removal of contamination. It may involve pressure washing. Sometimes wash down involves rinsing with fresh water; other times it involves use ...
*
Wastewater Wastewater is water generated after the use of freshwater, raw water, drinking water or saline water in a variety of deliberate applications or processes. Another definition of wastewater is "Used water from any combination of domestic, industr ...


References


External links


Clean-in-place in pictures and diagrams

Clean in Place Sensors

Cleaning-in-place
{{DEFAULTSORT:Clean-In-Place Cleaning methods Environmental engineering